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British Steel
British Steel installs the latest filtration technology, which guarantees clean compressed air, saving the site over £72,000.
Ready to Stop Equipment Failure and Save Thousands?
Project Background:
Compressed air is essential for many processes at British Steel’s Scunthorpe site. Moisture in the compressed air lines was causing extensive damage to pneumatic equipment. Traditional compressed air filters were proving ineffective and could not offer consistent protection for equipment. Mechanical Improvement Engineer Andrew Hindley highlighted the baghouse dust collector and powder-blowing machines as the site’s primary concern.
The baghouse dust collector was experiencing a variety of problems caused by moisture. For example, the baghouse filter socks would clog and tear. When this happens, filter socks need replacing, and the site experiences unplanned shutdowns. A torn sock which contains harmful substances can cause dust pollution that may trigger a stack emissions monitor. If the emissions monitor is activated, the site must shut down. Moisture also causes particles in the socks to clog together, resulting in frequent air purges, which wastes energy and money.
Additionally, moisture damages the solenoid valves on the dust collector. Trapped moisture causes internal corrosion, and the piston can hydraulically lock so the valve opens and closes unpredictably. The only way to rectify this problem is to replace the damaged valves. Overall, moisture in the compressed air lines drastically increased refurbishment costs.
The powder-blowing machines for slab and bloom moulds were also experiencing issues with moisture in the compressed air system. Moisture in the airlines was again causing damage to the solenoid valves. Faulty solenoid valves were leading to the uncontrolled application of powder. The machines would apply a layer of powder, either too thick or too thin. The powder would then be applied manually, resulting in far higher labour costs.
Summary:
Application
Baghouse dust collector
Cost Saving
- Total: £72,260 (estimated).
- Sock Replacements: £27,000
- Sock cages and Spares: £6,000
- Pulse Control Panel: £11,000
- Labour Costs: £28,260
Payback Period
Less than a year.
Why Did British Steel Choose Expel?
Expel’s revolutionary filtration technology offers 99.999% efficiency and consistent performance regardless of the quality of compressed air that enters the unit. In contrast, a conventional filter contains disposable internal elements designed to trap and retain moisture. The performance of these elements deteriorates as the material becomes saturated. Expel ensures pneumatic equipment is always protected because it contains no disposable elements, so the performance never deteriorates.
Baghouses usually require refurbishment every 4 to 5 years. However, Scunthorpe’s baghouses needed refurbishment far more frequently due to the large volume of water in the compressed air system. The engineer installed an Expel unit next to the baghouse dust collector. The results of installing a solution of this calibre became apparent almost instantly.
Expel removed approximately 250ml of moisture every two days.
By guaranteeing continual moisture removal, Expel has drastically reduced the refurbishment frequency of the baghouse.
Due to Expel’s unparalleled performance, they installed a second Expel unit next to the powder-blowing machine. Expel again proved to be the perfect tool to eradicate the problem of solenoid valve failures caused by liquid water.
The Results:
- Reduced Costs: For every refurbishment Expel reduces for the site, Expel saves the site an estimated £72,260.
- Reduced Energy Usage: By stopping the baghouse filter socks from getting clogged, the site no longer had to purge the clogged socks frequently. Therefore, Expel prevents compressed air (and thus energy) wastage.
- Superior Equipment Protection: By removing all liquid water, oil emulsion fluids and solid particulates down to 1 micron, Expel guarantees that pneumatic equipment is protected to a consistently high standard.
- Reduced Maintenance: By ensuring clean compressed air, Expel has eliminated the time spent rectifying unplanned shutdowns. Whenever a solenoid valve or filter sock needed replacing, the site experienced production downtime. Expel has, therefore, drastically increased productivity.
Our team is ready to answer your questions.
David specialises in improving business efficiency. By building strong industry relationships, David ensures Expel’s revolutionary technology delivers real value to businesses.
With vast pneumatics knowledge, Johan specialises in on-site assessments to identify strategic installation points to maximise performance and eradicate contamination.
Lauren is a key point of contact for customers. She handles general inquiries and provides exceptional after-sales support, ensuring a smooth customer experience.